U.S. patent application number 10/024493 was filed with the patent office on 2003-06-26 for novel leg cuff configuration.
Invention is credited to Johnson, Betsy.
Application Number | 20030120244 10/024493 |
Document ID | / |
Family ID | 21820862 |
Filed Date | 2003-06-26 |
United States Patent
Application |
20030120244 |
Kind Code |
A1 |
Johnson, Betsy |
June 26, 2003 |
Novel leg cuff configuration
Abstract
Absorbent articles having a novel leg cuff configuration,
methods for using same and methods for preparing same, are
disclosed. In particular, the absorbent articles comprise a polymer
barrier and a pair of leg cuffs configured to provide unexpectedly
superior comfort for wearers of the absorbent articles. The
absorbent articles further unexpectedly provide superior fit about
the legs of the wearer and consequentially superior lateral leak
protection.
Inventors: |
Johnson, Betsy; (Atlanta,
GA) |
Correspondence
Address: |
Christopher C. Campbell, Esq.
Hunton & Williams
Suite 1200
1900 K Street, NW
Washington
DC
20006-1109
US
|
Family ID: |
21820862 |
Appl. No.: |
10/024493 |
Filed: |
December 21, 2001 |
Current U.S.
Class: |
604/385.27 ;
604/385.23 |
Current CPC
Class: |
A61F 13/51474 20130101;
A61F 13/514 20130101; A61F 2013/49092 20130101; A61F 13/4942
20130101; A61F 13/475 20130101; A61F 13/51478 20130101 |
Class at
Publication: |
604/385.27 ;
604/385.23 |
International
Class: |
A61F 013/15; A61F
013/20 |
Claims
What is claimed is:
1. An absorbent article comprising: a substantially impermeable
backsheet; a permeable topsheet; an absorbent core disposed between
the substantially impermeable backsheet and the permeable topsheet;
a pair of elastic leg cuffs comprising a soft nonwoven material,
each of said elastic leg cuffs being disposed adjacent to the
longitudinal side edges of the absorbent article; and a polymer
barrier disposed between the substantially impermeable backsheet
and the absorbent core, said polymer barrier being transversely
positioned between the elastic leg cuffs, such that the transverse
width of the polymer barrier is at least the transverse width of
the absorbent core and the transverse width of the polymer barrier
is no greater than the distance between the innermost portion of
each of the elastic leg cuffs.
2. The absorbent article of claim 1, wherein the soft nonwoven
material comprises fibers selected from the group consisting of
spun-laced fibers, spun-bonded fibers, melt-blown fibers and
combinations thereof.
3. The absorbent article of claim 1, wherein the soft nonwoven
material comprises fibers of about 1.00 dtex to about 3.50
dtex.
4. The absorbent article of claim 1, wherein the soft nonwoven
material comprises fibers of about 1.25 dtex to about 3.00
dtex.
5. The absorbent article of claim 1, wherein the soft nonwoven
material comprises fibers of about 1.25 dtex to about 2.75
dtex..
6. The absorbent article of claim 1, wherein said soft nonwoven
material has a basis weight in the range of about 0.3-0.8 ounces
per square yard.
7. The absorbent article of claim 1, wherein the soft nonwoven
material is selected from the group consisting of polyester,
polypropylene, polyethylene and combinations thereof.
8. The absorbent article of claim 1, wherein the leg cuffs are
directly bonded to the substantially impermeable backsheet.
9. The absorbent article of claim 1, wherein the leg cuffs are
directly bonded to the substantially impermeable backsheet and the
permeable topsheet.
10. The absorbent article of claim 1, wherein the absorbent core is
approximately rectangular.
11. The absorbent article of claim 1, wherein the polymer barrier
is approximately rectangular.
12. The absorbent article of claim 1, wherein the substantially
impermeable backsheet comprises the soft nonwoven material 1.
13. The absorbent article of claim 1, wherein the soft nonwoven
material is selected from the group consisting of polyester fibers,
polypropylene fibers, polyethylene fibers and combinations
thereof.
14. The absorbent article of claim 1, wherein the polymer barrier
is positioned on said absorbent article so as to not come into
contact with the legs of the wearer of the absorbent article during
use.
15. The absorbent article of claim 1, further comprising a pair of
inner leg gathers disposed on the permeable topsheet, each of said
inner leg gathers being positioned outward of a side edge of the
absorbent core and inward of the nearest leg cuff.
16. The absorbent article of claim 1, wherein the transverse width
of the polymer barrier is greater than the transverse distance
between each of the inner leg gathers.
17. An absorbent garment comprising front and rear waist portions
cooperating to form a waist opening; a crotch region formed between
said front and rear waist portions; a pair of leg openings on
opposed sides of the crotch region; a permeable topsheet; a
substantially impermeable backsheet; an absorbent core disposed
between the permeable topsheet and the substantially impermeable
backsheet; a pair of stand-up elasticized leg gathers having a
distal edge and a proximal edge and positioned inward of said leg
openings on opposite sides of a longitudinal center line of the
absorbent garment, said leg gathers comprising a non-woven
material; a pair of elastic leg cuffs comprising a soft nonwoven
material, each of said elastic leg cuffs being disposed adjacent to
the longitudinal side edges of the absorbent article; and a polymer
barrier disposed between the substantially impermeable backsheet
and the absorbent core, said polymer barrier being transversely
positioned between the elastic leg cuffs, such that the transverse
width of the polymer barrier is at least the transverse width of
the absorbent core and the transverse width of the polymer barrier
is no greater than the distance between the innermost portion of
each of the elastic leg cuffs.
18. The absorbent garment of claim 17, said permeable topsheet
having a basis weight of about 0.6 ounces per square yard, said
permeable topsheet comprising a central liquid permeable portion
and a pair of side marginal portions joined to respective opposite
side edges of said central portion, said side marginal portions
comprising spun-bond, melt-blown, spun-bond (SMS) non-woven
material having a basis weight in the range of about 0.3-0.8 ounces
per square yard, said central portion of said topsheet comprising a
spun-bond polypropylene non-woven fabric.
19. The absorbent garment of claim 17, said substantially
impermeable backsheet comprising a non-woven material selected from
the group consisting of spun-laced fibers, spun-bonded, melt-blown
fibers and combinations thereof.
20. The absorbent garment of claim 17, wherein said fibers comprise
a material selected from the group consisting of polyester,
polypropylene, polyethylene and combinations thereof.
21. The absorbent article of claim 17, wherein the polymer barrier
is positioned on said absorbent article so as to not come into
contact with the legs of the wearer of the absorbent article during
use.
22. An absorbent garment comprising: front and rear waist portions
cooperating to form a waist opening; a crotch region formed between
said front and rear waist portions; a pair of leg openings on
opposed sides of the crotch region; a permeable topsheet, a
substantially impermeable backsheet, and an absorbent core
positioned between said permeable topsheet and said substantially
impermeable backsheet; a pair of elastic leg cuffs comprising a
soft nonwoven material, each of said elastic leg cuffs extending at
least through the crotch region adjacent to each leg opening and
positioned between said permeable topsheet and substantially
impermeable backsheet; and a polymer barrier disposed between the
substantially impermeable backsheet and the absorbent core, said
polymer barrier being transversely positioned between the elastic
leg cuffs, such that the transverse width of the polymer barrier is
at least the transverse width of the absorbent core and the
transverse width of the polymer barrier is no greater than the
distance between the innermost portion of each of the elastic leg
cuffs.
23. The absorbent garment of claim 22, wherein the soft nonwoven
material comprises fibers selected from the group consisting of
spun-laced fibers, spun-bonded fibers, melt-blown fibers and
combinations thereof.
24. The absorbent garment of claim 22, wherein the soft nonwoven
material is selected from the group consisting of polyester,
polypropylene, polyethylene and combinations thereof.
25. The absorbent article of claim 22, wherein the polymer barrier
is positioned on said absorbent article so as to not come into
contact with the legs of the wearer of the absorbent article during
use.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of
absorbent articles, and more particularly to absorbent articles
having a novel leg cuff configuration, methods for using same and
methods for preparing same. In particular, the present invention
relates to absorbent articles having unexpectedly superior fit,
distribution, comfort, leak protection, skin protection, absorbency
and/or cost-efficiency, and methods for using same and methods for
preparing same.
BACKGROUND OF THE INVENTION
[0002] Disposable absorbent articles typically include a
moisture-impervious backing sheet, an absorbent pad, and a liner
sheet that contacts the body of a person wearing the article. In
addition, elasticized regions are provided around the edges of the
article to secure the article about the waist and legs of a wearer.
Absorbent articles, such as disposable diapers, typically further
comprise opposed front and rear waist portions defining a waist
opening, a crotch portion disposed therebetween, and a pair of
elastically contractible leg openings along the side edges of the
crotch portion. Disposable diapers having elasticized margins for
placement about the legs of a wearer are disclosed in U.S. Pat. No.
4,050,462 and U.S. Pat. No. 5,092,861, and disposable diapers
having elasticized side margins and waist band margins are
disclosed in U.S. Pat. No. 4,300,562. Further, disposable diapers
are conventionally fastened to the body of a user using various
attachment means, including adhesive tapes, velcro tapes,
spring-like clasps and flaps.
[0003] Problems with such diaper designs include shifting, shearing
and conflicting movements of the article and the body of a wearer,
which distort the article, and thereby cause uneven distribution of
the article relative to the wearer's body and/or cause the article
to move away from a position in which it is able to reliably and
intimately contact the wearer's body. Such distortions cause
discomfort and often result in lateral leakage of urinary or fecal
material from the diaper. Further, prolonged contact of liquid or
semi-solid excreta with the skin of the wearer is also aggravated
under such circumstances. For example, the moisture vapor and heat
generated by the bodily exudate accumulate in a pocket of the
diaper, becoming trapped and then leading to conditions adjacent to
a wearer's skin that promote skin irritation, infection, and the
like. Although a plastic backsheet, as described above, is
generally effective in precluding the passage of bodily exude
outwardly, the backsheet is not efficient in preventing lateral
leakage of liquids from the opposed side portions of the core
sideward between the leg gathers of the backsheet and the wearer's
skin. One solution to this problem, the tightening of leg gathers
or leg cuffs, presents problems in terms of the comfort of the baby
and further skin irritation, particularly in view of the
conventional use of polymer linings on the leg cuffs.
[0004] Despite previous advancements in the field of absorbent
articles, persons of ordinary skill in the art continue their
efforts to produce garments that fit better and thus are more
comfortable and better able to contain urinary and fecal
excretions. Various approaches have been attempted to improve fit
and comfort of absorbent articles, while reducing lateral leakage
of liquids from such articles. However, these approaches are all
deficient in terms of effectiveness and/or cost-efficiency.
[0005] For example, U.S. Pat. No. 6,114,596 to Nayak et al.
discloses a breathable diaper, feminine hygiene, or like disposable
sanitary product having a cloth-like outer surface and including a
plurality of materials from the skin-facing side outwardly, a
topsheet, a core, an optional barrier, and a backsheet. The
disclosed topsheet is formed of liquid- and vapor-permeable
hydrophilic material, and the core is formed of highly absorbent
material disposed outwardly of the topsheet for absorbing liquid
received through the topsheet. The disclosed core has an inter
surface in liquid communication with the topsheet and an outer
surface. The disclosed optional barrier is formed for a multi-layer
non-woven material which is hydrophobic and vapor-permeable for
limiting the outward escape of liquid therethrough while enabling
the outward escape of heat and water vapor therethrough. The
disclosed barrier has a base disposed adjacent the core outer
surface. The disclosed backsheet is formed of a multi-layer
non-woven material which is hydrophobic and vapor permeable for
limiting the outward escape of liquid therethrough while enabling
the outward escape of heat and water vapor therethrough. This
backsheet is disclosed as being disposed at least partially as an
outer surface of the diaper.
[0006] U.S. Pat. No. 6,017,336 to Sauer discloses an absorbent
article which includes a pair of compression resistant containment
barriers which are configured to inhibit the lateral flow of fecal
exudates along the surface of the absorbent article. The
containment barriers are disclosed as being laterally spaced apart
to provide a void space between the wearer's back side and the
surface of the absorbent article for containing body exudates. Each
containment barrier is disclosed as defining a width to height
ratio of at least about 0.5 and a compression resistance of at
least about 50%. The absorbent article is disclosed as optionally
including a containment dam which is located on the body facing
surface of the absorbent article and which is configured to inhibit
a longitudinal flow of fecal exudates along the surface of the
absorbent article.
[0007] U.S. Pat. No. 5,843,066 discloses a disposable absorbent
article having a breathable laminate backsheet. The absorbent
article has a front waist region, a rear waste region, a crotch
region positioned between the front waist region and the rear waste
region, a pair of opposed side edges, a first end edge and a second
end edge. The absorbent article includes an absorbent core having a
pair of opposing longitudinal edges, a garment-facing side of the
absorbent core. The breathable laminate backsheet has an inner
layer and an outer layer joined to one another. The inner layer is
positioned between the absorbent core and the outer layer. The
outer layer is relatively vapor pervious. The inner layer is
substantially liquid, vapor and air impermeable. The inner layer is
longitudinally coterminous with the absorbent article and of a
smaller transverse width than the front waist region, the rear
waste region, and the crotch region so as to form a breathable zone
which is longitudinally coterminous with the absorbent article and
adjacent to each of the side edges.
[0008] U.S. Pat. No. 5,597,906 to Roe, et al. discloses an
absorbent article comprising a liquid pervious topsheet, a liquid
pervious backsheet joined to at least a portion of the topsheet, an
absorbent cord disposed between at least a portion of the topsheet
and the backsheet, and a waste management element disposed in at
least a portion of the crotch region. The waste management element
preferably has an acceptance under pressure value of greater than
about 0.50 grams of a viscous fluid bodily waste per square inch of
the waste management element milliJoule of energy input. The waste
management element is also disclosed as having a storage under
pressure values of at least about 0.70 grams of the viscous fluid
bodily waste per square inch of the waste management element. The
waste management element is also disclosed as optional having an
Immobilization Under Compressed Inversion valve of greater than
about 70% of the viscous fluid bodily waste accepted by the waste
management element. The waste management is disclosed as being
located anywhere in the article, including the crotch region.
[0009] U.S. Pat. No. 5,941,864 to Roe discloses a disposable
absorbent article, such as a diaper having a first topsheet with
apertures large enough for low-viscosity fecal material to pass
through to a fecal material storage element. The fecal material
storage element is disclosed as immobilizing the fecal material in
position for dewatering, so that the liquid components of the fecal
material are absorbed by the core and solid components of the fecal
material are separated from the liquid components, to provide for
easier cleaning of the wearer when the soiled disposable absorbent
article is removed.
[0010] U.S. Pat. No. 5,941,862 to Haynes et al. discloses absorbent
structures comprising a first layer, a second layer juxtaposed in
facing relation with said first layer, wherein at least one of the
layers is fluid pervious. These structures are disclosed as having
a continuous region between said first and second layers comprising
hydrogel-forming polymer that is substantially uniformly
distributed throughout the region. The continuous region is
disclosed as at least partially surrounding multiple, spaced apart
zones between said layers, which zones are substantially devoid of
hydrogel-forming absorbent polymer. The first and second layers are
disclosed as being bonded together such that said hydrogel-forming
absorbent polymer is substantially immobilized when in dry state,
an preferably at sites within plurality of the zones.
[0011] U.S. Pat. No. 5,558,655 to Jezzi et al. discloses in
absorbent article, such as diaper, which comprises a composite
structure of a "two-dimensional" or very flat, apertured film or
nonwoven layer, in combination with a fluid transferring layer and
a superabsorbent polymer-containing laminate, and a absorbent core
below the laminate to achieve superior dryness. The superabsorbent
polymer-containing laminate is disclosed as containing airlaid
fibrous components and superabsorbent polymers and as swelling to
at least three times its dry caliper upon fluid introduction in
order to achieve movement of the coverstock away from the absorbent
core which permits the coverstock to remain relatively dry and
avoids rewetting.
[0012] U.S. Pat. No. 6,040,251 to Caldwell discloses barrier webs
at a certain desirable physical qualities such as water resistance,
increased durability, improved barrier qualities and the like.
Barrier webs are disclosed as comprising a web that has been
treated with a curable shear thinned thixotropic polymer
composition which is adapted to be substantially impermeable to
liquids, permeable to gases and impermeable to microorganisms.
Further, the barrier webs are disclosed as being either impermeable
to all microorganisms or impermeable to microorganisms of certain
sizes. Also disclosed are fabrics that are capable of either
selectively binding certain microorganisms, particles, or molecules
depending upon what binding partners are incorporated into the
polymer before application to the fabric.
[0013] U.S. Pat. No. 5,945,175 to Yahiaoui et al discloses a coated
porous substrate composed of a hydrophobic polymer which is
substantially uniformly coated with a hydrophilic polymeric
material. The substrate may be a sheet-like material, examples of
which are forms, fibers, and fibrous webs. The fibrous webs are
disclosed as desirably being nonwoven webs. The coating on the
substrate is disclosed as being durable to an aqueous medium at a
temperature in a range of from about 10.degree. C. to about
50.degree. C. and does not significantly suppress the surface
tension of an aqueous medium with which the coated substrate may
come in contract. The hydrophobic polymer is disclosed as being a
polyolefin, such as polyethylene or polypropylene. The hydrophilic
polymeric material is disclosed as being a polysaccharide or a
modified polysaccharide.
[0014] U.S. Pat. No. 6,117,121 to Faulks et al. discloses an
absorbent article including an absorbent core located between a
bodyside liner and an outer cover. The absorbent article is
disclosed as having a leg cuff mounted to a base structure in the
crotch portion thereof. The leg cuffs are disclosed as being
partially stretched when attached to respective longitudinal side
portions near the crotch portion of the absorbent article.
[0015] U.S. Pat. No. 6,107,539 to Palumbo et al. discloses
disposable absorbent articles comprising a backsheet, a topsheet, a
fluid acquisition/distribution region and at least one fluid
storage region, said article having a total product acquisition
performance of more than 3.75 ml/sec in the first gush and more
than 0.5 ml/sec in the fourth gush and an in bag stack height of
less than 9.9 mm, characterized in that said topsheet allows it to
retain no more then 0.25 g of fluid as measured by the
topsheet-on-acquisition-material-wetness test, and that said
acquisition/distribution region has a drip capacity of at least 5.0
grams of fluid per gram of material.
[0016] U.S. Pat. No. 5,935,118 to Gryskiewicz et al. discloses an
absorbent article that includes a garment shell and at least one
liquid containment beam formed of an absorbent material. The liquid
containment beam has an attachment edge bonded to the garment shell
so that the containment beam can lie against the garment shell and
also pivot about an axis defined by the attachment edge. For
comfort during use, the containment beam desirably has a width to
thickness ratio of at least about 3:1. In particular embodiments,
the absorbent article includes pairs of inner and outer containment
beams, with the inner containment beams adapted to lie against the
garment shell and the outer containment beams adapted to lie
against the inner containment beams.
[0017] U.S. Pat. No. 6,087,550 to Anderson-Fischer et al. relates
to water responsive thermoplastic compositions and articles
constructed thereof. This invention particularly relates to
thermoplastic copolyester compositions useful for the manufacture
of disposable articles such as disposable diapers and feminine
napkins. More particularly, this invention relates to thermoplastic
copolyester compositions that are useful as a raw material in the
manufacture of nonwovens, barrier films or coatings, as well as for
various improved hot melt adhesive compositions useful for
incorporating hydrophilic features into disposable articles.
[0018] U.S. Pat. No. 6,120,783 to Roe et al. discloses web
materials which have two or more skin care compositions disposed
thereon. The skin care compositions are transferable to the
wearer's skin by normal contact and/or wearer motion and/or body
heat. The skin care compositions disclosed in the present invention
are selected to maintain and/or improve the skin health of the
wearer upon transfer during use, for example, to provide a skin
protective barrier or a therapeutic benefit; to minimize the
abrasion between the cuffs and skin in the area where the cuffs
contact the wearer's skin, resulting in less skin irritation; to
improve BM clean up on the skin, or to improve the barrier
properties of the cuffs. Web materials of the present invention
have a wide range of potential uses in both durable and disposable
articles, but are particularly well suited for use in disposable
absorbent articles such as disposable diapers, incontinent briefs,
training pants, sanitary napkins, and the like.
[0019] U.S. Pat. No. 5,683,809 to Freeman et al. discloses
protective articles such as diapers, having filmless hydrophobic
barrier elements such as cuffs and backing sheets. The barrier
cuffs--which can be, for instance, leg cuffs and waistbands--and
the backing sheets can be provided from fabrics having a fabric
weight of at least 10 gsy.
[0020] U.S. Pat. No. 5,928,209 to Bodford et al. discloses a
breathable diaper, feminine hygiene, or like disposable sanitary
product construction includes a plurality of materials including,
from the skin-facing side outwardly, a topsheet of liquid- and
vapor-permeable hydrophilic material. A core of highly absorbent
material is disposed outwardly of the topsheet for absorbing fluid
received through the topsheet, the core having an inner surface in
fluid communication with the topsheet. A backsheet is disposed at
least partially as an outer surface of the construction and is
formed of a pouch defined by two layers of a non-woven hydrophobic
and vapor-permeable material, with absorbent or superabsorbent
particles therebetween, so that the backsheet limits the outward
escape of liquid therethrough while enabling the outward escape of
heat and water vapor therethrough. Each backsheet layer is an at
least two-layer spunbound-meltblown SM or an at least three-layer
spunbond-meltblown-spunbond SMS.
[0021] U.S. Pat. No. 5,990,377 to Chen et al. discloses a
dual-zoned, three-dimensional, resilient absorbent web is disclosed
which is suitable as body-side liner for absorbent articles such as
feminine pads, diapers and the like. When used as a liner in
absorbent articles, the dual-zoned web combines the advantages of
apertured films and soft, nonwoven cover layers in one structure
while still being inherently hydrophilic. The liner comprises a web
of wet-resilient, hydrophilic basesheet having a three-dimensional
topography comprising elevated regions onto which hydrophobic
matter is deposited or printed and a plurality of spaced apart
depressed regions. In a preferred embodiment, the hydrophobic
matter applied to the elevated regions of the basesheet comprises
hydrophobic fibers in a contiguous nonwoven web which has been
apertured or provided with slits or other openings, such that the
apertures or openings overlay a portion of the depressed regions.
The elevated hydrophobic regions enhance dry feel and promote fluid
flow toward the lower hydrophilic regions, which comprise the
exposed depressed regions of the basesheet. The basesheet is
preferably in liquid communication with underlying absorbent
material, most preferably a stabilized airlaid cellulosic material
or compressed stabilized fluff such that the absorbent material can
wick fluid out of the basesheet by capillary action. When soft,
hydrophobic fibers are deposited on the elevated regions, the liner
also has a soft, cloth-like feel in addition to a dry feel in
use.
[0022] U.S. Pat. No. 6,120,488 to VanRijswijck et al. discloses an
absorbent article, such as a diaper, containing cuffs and a
topsheet with one or more skin care compositions disposed thereon.
The skin care compositions are transferable to the wearer's skin by
normal contact and/or wearer motion and/or body heat. The skin care
compositions disclosed in the present invention are selected to
maintain and/or improve the skin health of the wearer upon transfer
during use, for example, to provide a skin protective barrier or a
therapeutic benefit; to minimize the abrasion between the cuffs and
skin in the area where the cuffs contact the wearer's skin,
resulting in less skin irritation; to improve BM clean up on the
skin, or to improve the barrier properties of the cuffs.
[0023] U.S. Pat. No. 5,817,079 to Bergquist et al. discloses in
absorbent products, such as sanitary napkins, discreet areas of dry
fibrous materials such as fluid-repellent materials are precisely
placed in various planes within the product so as to provide
barriers to bodily fluid leakage from the product. In a preferred
embodiment, hydrophobic fibers are placed around the periphery of a
central absorbent area of an absorbent product to discourage and/or
prevent side or end leakage from the product.
[0024] U.S. Pat. No. 5,830,201 to George et al. discloses a
flushable diaper for use on the body of an infant or adult. An
envelope has inner and outer walls which are secured together at
their outer periphery to form an inner cavity. The outer wall is
comprised of a hydrophobic outer layer together with a hydrophilic
inner layer. The inner wall is comprised of a hydrophobic outer
layer together with a hydrophilic inner layer. The inner and outer
walls are separated by an interior cavity which contains one or
more containers. The container is comprised of either a single
layer or a laminated wall which forms a chamber that encloses a
charge of water. The laminated wall is comprised a hydrophobic
inner laminate and a hydrophilic outer laminate. When manually
ruptured, the containers release water into the double walled
envelope, which causes disintegration of the hydrophilic inner
layers of the double walls, along with the hydrophobic outer
layers. An absorbent member is carried on the inner wall of the
envelope, and the absorbent member comprises a fluid pervious cover
which encloses an inner body that is comprised of a material which
is sufficiently hydrophilic to absorb urine and other fluids from
the body while maintaining structural integrity of the inner body
and to also absorb water in an effective amount to cause the inner
body to disintegrate into small pieces.
[0025] U.S. Pat. No. 5,885,266 to Chihani et al. discloses an
absorbent article such as a diaper, an incontinence guard or a
sanitary napkin includes a liquid-permeable outer sheet, a
liquid-impermeable bottom sheet and an absorbent body placed
therebetween. The outer sheet and the absorbent body are at least
partially joined together with a hydrophilic glue.
[0026] EP 0 850 628 A1 to Wierlacher disposes a tri-dimensional
disposable sanitary napkin having a body facing surface and a
garment facing surface, a longitudinal symmetry plane, a front end
edge and a rear end edge, and comprising a liquid pervious
topsheet, a backsheet joined to said topsheet and an absorbent core
intermediate the backsheet and the topsheet. The absorbent core has
a front portion, a central portion and a rear portion, and
comprises a longitudinally oriented ridge in the central and rear
portion having a profile that provides for an increased body fit.
The sanitary napkin is intended for direct attachment to the skin
of the wearer and comprises an adhesive on the body facing
surface.
[0027] EP 0 850 627 A1 to Hirsch relates to disposable absorbent
articles capable of self shaping in use as sanitary napkins or
pantiliners. In particular, the disclosure relates to such
disposable absorbent articles which are worn by direct attachment
to the skin of the wearer in the area were absorption of bodily
liquids is desired and which are activated during use to adapt
their shape to the negative three dimensional image of a wearer.
The topical adhesive attachment of such articles needs to be secure
and pleasing upon application and during use of such articles, yet
cause no discomfort upon removal of the article. This is achieved
by selecting the rheological characteristics of adhesives for such
articles.
[0028] EP 0 850 626 A1 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. In particular, the disclosure relates to
such disposable absorbent articles which are worn by direct
attachment to the skin of the wearer in the area were absorption of
bodily liquids is desired. The topical adhesive attachment of such
articles needs to be secure and pleasing upon application and
during use of such articles, yet cause no discomfort upon removal
of the article. It is disclosed that in order to provide additional
comfort the articles are adaptable, and preferably elastically
adaptable.
[0029] European Patent 0 850 625 A1 relates to disposable absorbent
articles particularly sanitary napkins, pantiliners, adult
incontinence products which have side cuffs or baby diapers. In
particular, the disclosure relates to such disposable absorbent
articles with side cuffs which are maintained in their in use
position by direct attachment to the skin of the wearer. The
topical adhesive attachment of such side cuffs needs to be secure
and pleasing upon application and during use of such articles, yet
cause no discomfort upon removal of the article. This is achieved
by selecting the rheological characteristics of adhesives for such
articles.
[0030] European Patent 0 850 624 A1 relates to disposable absorbent
articles particularly sanitary napkins, pantiliners, adult
incontinence products or sweat pads. In particular, the disclosure
relates to such disposable absorbent articles which are worn by
direct attachment to the skin of the wearer in the area were
absorption of bodily liquids is desired.
[0031] EP 0 850 623 A1 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. In particular, the disclosure relates to
such disposable absorbent articles which are worn by direct
attachment to the skin of the wearer in the area were absorption of
bodily liquids is desired and which articles are provided with an
odor control system.
[0032] EP 0 850 622 A1 relates to breathable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. In particular, the disclosure relates to
such breathable absorbent articles which are worn by direct
attachment to the skin of the wearer in the area were absorption of
bodily liquids is desired.
[0033] EP 0 850 621 A1 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. In particular, the disclosure relates to
such disposable absorbent articles which are worn by direct
attachment to the skin of the wearer in the area were absorption of
bodily liquids is desired. According to the disclosure, in order to
provide the articles with additional comfort they are adaptable,
and preferably elastically adaptable.
[0034] EP 0 850 620 A1 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products which have side cuffs or baby diapers. In particular, the
disclosure relates to such disposable absorbent articles with side
cuffs which are maintained in their in use position by direct
attachment to the skin of the wearer.
[0035] EP 0 850 619 A1 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. In particular, the disclosure relates to
such disposable absorbent articles which are worn by direct
attachment to the skin of the wearer in the area were absorption of
the bodily liquids is desired.
[0036] EP 0 850 618 A1 relates to absorbent articles capable of
self shaping in use, particularly sanitary napkins or pantiliners.
In particular, the disclosure relates to such disposable absorbent
articles which are worn by direct attachment to the skin of the
wearer in the area were absorption of bodily liquids is desired and
which are activated during use to adapt to their shape to the
negative three dimensional image of a wearer.
[0037] WO 00/07636 relates to disposable absorbent articles such as
diapers and sanitary napkins which are provided with adhesive for
attachment of the article to the skin which adhesives provide
secure attachment and are pleasing to the skin upon application,
yet cause no discomfort upon removal.
[0038] WO 98/28024 relates to topical adhesives for attachment to
the skin. In particular, the disclosure relates to such topical
adhesives which can be employed for attachment to the skin of
protective articles, clothing, prosthesis, heat wraps, pads, and/or
packs, e.g. for topical relief of pain or simply to provide
warming; cold wraps, hearing aids, protective face masks,
ornamental articles, or eye wear but excluding absorbent articles.
The topical adhesives provides secure attachment and is pleasing to
the skin upon application, yet causes no discomfort upon removal.
This is achieved by selecting the chemical composition and
rheological characteristics of the topical adhesives.
[0039] WO 98/28021 relates to topical adhesives for attachment to
the skin. In particular, the disclosure relates to such topical
adhesives which can be employed for attachment to the skin of
articles such as protective articles, clothing, prothesis, heat
wraps, pads, and/or packs, e.g. for topical relief of pain or
simply to provide warmth; cold wraps, hearing aids, protective face
masks, ornamental articles or eye wear, but excluding absorbent
articles, or also of functional articles such as cosmetic or
pharmaceutical delivery articles that provide a substance to the
skin, decorative cosmetics or cleaning articles. The topical
adhesive provides secure attachment and is pleasing to the
particularly the viscous modulus G" in combination with the
thickness C of the topical adhesive layer in which the adhesive is
provided for attachment to the skin.
[0040] WO 98/28017 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products which have side cuffs or baby diapers. In particular, the
disclosure relates to such disposable absorbent articles with side
cuffs which are maintained in their in-use position by direct
attachment to the skin of the wearer.
[0041] WO 98/28016 relates to topical adhesives for attachment to
the skin. In particular, the disclosure relates to such topical
adhesives which can be employed for attachment to the skin of
protective articles, clothing, prosthesis, heat wraps, pads, and/or
packs, cold wraps, hearing aids, protective face masks, ornamental
articles, or eye wear but excluding absorbent articles. The topical
adhesive provides secure attachment and is pleasing to the skin
upon application, yet causes no discomfort and a low level of
adhesive residues on the skin upon removal. This is achieved by
selecting the chemical composition and rheological characteristics
of the topical adhesives, in particular with reference to the
relationship between the elastic modulus G' and the viscous modulus
G" of the adhesive.
[0042] WO 98/28014 relates to topical adhesives for attachment to
the skin. In particular, the disclosure relates to such topical
adhesives which can be employed for attachment to the skin in the
area where absorption of bodily liquids is desired. The topical
adhesive provides secure attachment and is pleasing to the skin
upon application, yet causes no discomfort upon removal. This is
achieved by selecting the chemical composition and rheological
characteristics of the topical adhesives, particularly the viscous
modulus G" in combination with the thickness C of the topical
adhesive layer applied to the absorbent article for attachment to
the skin.
[0043] WO 98/27918 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. In particular, the disclosure relates to
such disposable absorbent articles which are worn by direct
attachment to the skin of the wearer in the area where absorption
of bodily liquids is desired. The topical adhesive attachment of
such articles needs to be secure and pleasing upon application and
during use of such articles, yet cause no discomfort upon removal
of the article. This is achieved by selecting the rheological
characteristics of adhesives for such articles.
[0044] WO 98/27917 relates to disposable articles, particularly
sanitary napkins, pantiliners, adult incontinence products which
have side cuffs, or baby diapers. In particular, the disclosure
relates to such disposable absorbent articles with side cuffs which
are maintained in their in-use position by direct attachment to the
skin of the wearer. The topical adhesive attachment of such side
cuffs needs to be secure and pleasing upon application and during
use of such articles, yet cause no discomfort upon removal of the
article. This is achieved by selecting the rheological
characteristics of adhesives for such articles.
[0045] WO 98/27916 relates to disposable absorbent articles capable
of self-shaping in use, particularly sanitary napkins or
pantiliners. In particular, the disclosure relates to such
disposable absorbent articles which are worn by direct attachment
to the skin of the wearer where absorption of bodily liquids is
desired and which are activated during use to adapt their shape to
the negative three-dimensional image of a wearer. The topical
adhesive attachment of such articles needs to be secure and
pleasing upon application and during use of such articles, yet
cause no discomfort upon removal of the article. This is achieved
by selecting the rheological characteristics of adhesives for such
articles.
[0046] WO 98/27915 relates to disposable articles particularly
sanitary napkins, pantiliners, adult incontinence products or sweat
pads. In particular, the disclosure relates to such disposable
absorbent articles which are worn by direct attachment to the skin
of the wearer in the area where absorption of bodily liquids is
desired. The topical adhesive attachment of such articles needs to
be secure and pleasing upon application and during use of such
articles, yet cause no discomfort upon removal of the article.
[0047] WO 98/27913 relates to disposable absorbent articles capable
of self shaping in use particularly sanitary napkins or
pantiliners. Specifically disclosed are disposable absorbent
articles which are worn by direct attachment to the skin of the
wearer in the area where absorption of bodily liquids is desired
and which are activated during use to adapt their shape to the
negative three dimensional image of a wearer.
[0048] WO 98/27912 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. The disclosure relates to such disposable
absorbent articles which are worn by direct attachment to the skin
of the wearer in the area where absorption of bodily liquids is
desired and which are provided with an odour control system.
[0049] WO 98/27911 relates to breathable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. Disclosed are breathable absorbent articles
which are worn by direct attachment to the skin of the wearer in
the area where absorption of bodily liquids is desired.
[0050] WO 98/27910 relates to disposable absorbent articles
particularly sanitary napkins, pantiliners, adult incontinence
products or sweat pads. In particular, the disclosure relates to
such disposable absorbent articles which are worn by direct
attachment to the skin of the wearer in the area where absorption
of bodily liquids is desired.
[0051] WO 98/23305 relates to a polysiloxane adhesive composition
that is disclosed as being useful in attaching products to human
skin. It is disclosed that a disposable absorbent product may be
prepared that includes the polysiloxane adhesive composition and
that may be adhered directly to human skin and peeled off after use
with little or no pain to the wearer.
[0052] As is apparent from the foregoing, each of the above
discussed references presents a variety of means for improving fit
and comfort of certain types of absorbent articles, as well as for
controlling leakage in certain absorbent garments. However, all of
these proposed means are deficient in terms of effectiveness and
low product quality, mechanical complexity in design, specificity
of application and/or associated cost inefficiencies.
[0053] In view of the deficiencies of the various products and
processes disclosed in the above discussed references, it is highly
desirable to provide cost-efficient absorbent articles that display
superior fit, distribution, comfort, leak protection, skin
protection, absorbency and/or cost-efficiency. Further, it is
highly desirable to provide a cost-efficient process for producing
absorbent articles having superior fit, distribution, comfort, leak
protection, skin protection, absorbency and/or cost-efficiency, as
well as having broad applicability.
SUMMARY OF THE INVENTION
[0054] The present invention is directed to absorbent articles and
absorbent garments, as well as methods for preparing same and
methods for using same, that provide unexpectedly superior comfort
to a wearer, as well as unexpectedly superior fit and
consequentially superior leak protection. In particular, the
absorbent articles and garments of the present invention comprise a
polymer barrier and leg cuffs in a novel configuration. The present
absorbent articles and absorbent garments are also highly
cost-efficient.
[0055] An embodiment of the present invention provides an absorbent
article comprising: a substantially impermeable backsheet; a
permeable topsheet; an absorbent core disposed between the
substantially impermeable backsheet and the permeable topsheet; a
pair of elastic leg cuffs comprising a soft nonwoven material, each
of said leg cuffs being disposed adjacent to the longitudinal side
edges of the absorbent article; and a polymer barrier disposed
between the substantially impermeable backsheet and the absorbent
core, said polymer barrier being transversely positioned between
the leg cuffs, such that the transverse width of the polymer
barrier is at least the transverse width of the absorbent core and
the transverse width of the polymer barrier is no greater than the
distance between the innermost portion of each of the leg
cuffs.
[0056] A further embodiment of the present invention provides an
absorbent garment comprising: front and rear waist portions
cooperating to form a waist opening; a crotch region formed between
said front and rear waist portions; a pair of leg openings on
opposed sides of the crotch region; a permeable topsheet; a
substantially impermeable backsheet; an absorbent core disposed
between the permeable topsheet and the substantially impermeable
backsheet; a pair of stand-up elasticized leg gathers having a
distal edge and a proximal edge and positioned inward of said leg
openings on opposite sides of a longitudinal center line of the
absorbent garment, said leg gathers comprising a non-woven
material; a pair of elasticized leg cuffs comprising a soft
nonwoven material, each of said leg cuffs being disposed adjacent
to the longitudinal side edges of the absorbent article; and a
polymer barrier disposed between the substantially impermeable
backsheet and the absorbent core, said polymer barrier being
transversely positioned between the leg cuffs, such that the
transverse width of the polymer barrier is at least the transverse
width of the absorbent core and the transverse width of the polymer
barrier is no greater than the distance between the innermost
portion of each of the leg cuffs.
[0057] An even further embodiment of the present invention provides
an absorbent garment comprising: front and rear waist portions
cooperating to form a waist opening; a crotch region formed between
said front and rear waist portions; a pair of leg openings on
opposed sides of the crotch region; a permeable topsheet, a
substantially impermeable backsheet, and an absorbent core
positioned between said permeable topsheet and said substantially
impermeable backsheet; a pair of elasticized leg cuffs comprising a
soft nonwoven material, each of said leg cuffs extending at least
through the crotch region adjacent to each leg opening and
positioned between said permeable topsheet and substantially
impermeable backsheet; and a polymer barrier disposed between the
substantially impermeable backsheet and the absorbent core, said
polymer barrier being transversely positioned between the leg
cuffs, such that the transverse width of the polymer barrier is at
least the transverse width of the absorbent core and the transverse
width of the polymer barrier is no greater than the distance
between the innermost portion of each of the leg cuffs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0058] FIG. 1 is a top view of an absorbent article having a
polymer barrier in accordance with an implementation of the present
invention.
[0059] FIG. 2 is a cross-sectional view of an absorbent article
having a polymer barrier in accordance with the implementation of
the present invention illustrated in FIG. 1.
[0060] FIG. 3 is a top view of an absorbent article having a
polymer barrier in accordance with an implementation of the present
invention.
[0061] FIG. 4 is a cross-sectional view of an absorbent article
having a polymer barrier in accordance with the implementation of
the present invention illustrated in FIG. 3.
[0062] FIG. 5 is a top view of an absorbent article having a
polymer barrier in accordance with an implementation of the present
invention.
[0063] FIG. 6 is a cross-sectional view of an absorbent article
having a polymer barrier in accordance with the implementation of
the present invention illustrated in FIG. 5.
DETAILED DESCRIPTION OF THE INVENTION
[0064] As used herein, the term "absorbent article" refers to
articles that absorb and contain exudates, and more specifically
refers to articles which are placed against or in proximity to the
body of a wearer of the absorbent article to absorb and contain
various exudates discharged from the body. A non-exhaustive list of
examples of absorbent articles includes diapers, diaper cores,
diaper covers, disposable diapers, training pants, feminine hygiene
products and adult incontinence products. The term "disposable
article" refers to absorbent articles that are intended to be
discarded or partially discarded after a single use, i.e., they are
not intended to be laundered or otherwise restored or reused. The
term "unitary disposable absorbent article" refers to a disposable
absorbent article that is essentially a single structure (i.e., it
does not require separate manipulative parts such as a diaper cover
and insert). As used herein, the term "diaper" refers to an
absorbent article generally worn by infants and incontinent persons
about the lower torso.
[0065] The claims are intended to cover all of the forgoing classes
of absorbent articles, without limitation, whether disposable,
unitary or otherwise. These classifications are used
interchangeably throughout the specification, but are not intended
to limit the claimed invention. The invention will be understood to
encompass, without limitation, all classes of absorbent articles,
including those described above. Preferably, the absorbent core is
thin in order to improve the comfort and appearance of a garment.
The employance of thin, comfortable garments is disclosed, for
example without limitation in U.S. Pat. No. 5,098,423 to Pineiak et
al. which is herein incorporated by reference.
[0066] The present invention provides an absorbent article having
unexpectedly superior properties of absorbency, leakage protection
and/or skin wellness, as well as a method of preparing and a method
of using the absorbent article. In particular, the present
invention is directed to an absorbent article comprising: a
substantially impermeable backsheet; a permeable topsheet; an
absorbent core disposed between the substantially impermeable
backsheet and the permeable topsheet; a pair of elastic leg cuffs
comprising a soft nonwoven material, each of said leg cuffs being
disposed adjacent to the longitudinal side edges of the absorbent
article; and a polymer barrier disposed between the substantially
impermeable backsheet and the absorbent core, said polymer barrier
being transversely positioned between the leg cuffs, such that the
transverse width of the polymer barrier is at least the transverse
width of the absorbent core and the transverse width of the polymer
barrier is no greater than the distance between the innermost
portion of each of the leg cuffs.
[0067] Referring to FIG. 1, an absorbent article is shown from a
top perspective with the skin-facing surface of the permeable
topsheet 40 and the skin-facing surface of the substantially
impermeable backsheet 50 visible. The absorbent article comprises a
front edge 100, a back edge 110, two front-side edges 120a and
120b, two back-side edges 140a and 140b, and two leg cutout edges
130a and 130b, positioned such that leg cutout edge 130a is
disposed between front-side edge 120a and back-side edge 140a, and
leg cutout edge 130b is disposed between front-side edge 120b and
back-side edge 140b. The absorbent article further comprises two
inner leg gathers 2a and 2b, each of which extends longitudinally
along the topsheet of the absorbent article from the back edge 110
to the front edge 100. The inner leg gathers 2a and 2b are
approximately parallel to one another and are each positioned
approximately parallel to the front-side and back-side edges 120a,
120b, 140a and 140b. Further, each inner leg gather is located
adjacent to and inward of the inner most portion of the leg cutout
edges 130a and 130b. A pair of front wing regions are defined as
the area between each front-side edge and its adjacent inner leg
gather, forward of the leg cutouts. A pair of back wing regions are
defined as the area between adjacent back-side edge and its
adjacent inner leg gather, rearward of the leg cutouts.
[0068] As further shown in FIG. 1, the absorbent article further
comprises two leg cuffs 4a and 4b, each of which is positioned
approximately adjacent and parallel to each of the inner leg
gathers 2a and 2b. Each of the leg cuffs is located outward of said
inner leg gathers 2a and 2b. Two fasteners 6a and 6b are each
located at or near the back side edge of the absorbent article. An
absorbent core 8 is shown as being disposed between the permeable
topsheet 40 and a substantially impermeable backsheet 50 (not shown
in FIG. 1). The absorbent core 8 is positioned longitudinally along
the absorbent article. Waist foam is optionally present in the
absorbent article and positioned near and adjacent to the front
edge 100 and/or back edge 110, on the skin-facing surface of the
permeable topsheet 40.
[0069] Referring still to FIG. 1, a polymer barrier 10 is shown.
The polymer barrier 10 is disposed between the permeable topsheet
40 and the substantially impermeable backsheet 50. On the portion
of the absorbent article corresponding to the absorbent core 8, the
polymer barrier 10 is disposed between the absorbent core 8 and the
substantially impermeable backsheet 50. The polymer barrier 10 is
transversely positioned between the leg cuffs 4a and 4b and extends
from about the front edge 100 to about the back edge 110. The inner
leg gathers 2a and 2b are disposed on the skin-facing surface of
the permeable topsheet 40 and are bonded thereto.
[0070] Referring to FIG. 2, a cross-sectional view of an absorbent
article according to the implementation of the present invention
show in FIG. 1 is shown. The polymer barrier 10 is shown disposed
between the substantially impermeable backsheet 50 and the
permeable topsheet 40. Further, the polymer barrier 10 is shown as
being disposed between the absorbent core 8 and the substantially
impermeable backsheet 50 at the portion of the polymer barrier 10
that corresponds to the absorbent core 8.
[0071] Referring still to FIG. 2, the leg cuffs 4a and 4b are shown
as being positioned outward of the polymer barrier 10 and along the
permeable topsheet 40 and the substantially impermeable backsheet
50. In this manner, the leg cuffs 4a and 4b are bonded to the
permeable topsheet 40 and/or the substantially impermeable
backsheet 50. Accordingly, as illustrated in the figure, the leg
cuffs 4a and 4b are not bonded to the polymer barrier 10. Thus, the
leg cuffs 4a and 4b comprise the softer material of the permeable
topsheet 40 and/or the substantially impermeable backsheet 50
rather than the stiffer polymer material of the polymer barrier
10.
[0072] Referring to FIG. 3, an absorbent article is shown from a
top perspective with the skin-facing surface of the permeable
topsheet 40 and the skin-facing surface of the substantially
impermeable backsheet 50 visible. The absorbent article comprises a
front edge 100, a back edge 110, two front-side edges 120a and
120b, two back-side edges 140a and 140b, and two leg cutout edges
130a and 130b, positioned such that leg cutout edge 130a is
disposed between front-side edge 120a and back-side edge 140a, and
leg cutout edge 130b is disposed between front-side edge 120b and
back-side edge 140b. The absorbent article further comprises two
inner leg gathers 2a and 2b, each of which extends longitudinally
along the topsheet of the absorbent article from the back edge 110
to the front edge 100. The inner leg gathers 2a and 2b are
approximately parallel to one another and are each positioned
approximately parallel to the front-side and back-side edges 120a,
120b, 140a and 140b. Further, the innermost portion of each inner
leg gather is located adjacent to and inward of the innermost
portion of the leg cutout edges 130a and 130b. The outermost
portion of each of the inner leg gathers 2a and 2b extends beyond
the outermost portion of the permeable topsheet 40 and at least to
the nearest leg cuff 4a or 4b. Further, a pair of front wing
regions are defined as the area between each front-side edge and
its adjacent inner leg gather, forward of the leg cutouts. A pair
of back wing regions are defined as the area between adjacent
back-side edge and its adjacent inner leg gather, rearward of the
leg cutouts.
[0073] As further shown in FIG. 3, the absorbent article further
comprises two leg cuffs 4a and 4b, each of which is positioned
approximately adjacent and parallel to each of the inner leg
gathers 2a and 2b. Each of the leg cuffs is located outward of said
inner leg gathers 2a and 2b. Two fasteners 6a and 6b are each
located at or near the back side edge of the absorbent article. An
absorbent core 8 is shown as being disposed between the permeable
topsheet 40 and a substantially impermeable backsheet 50 (not shown
in FIG. 1). The absorbent core 8 is positioned longitudinally along
the absorbent article. Waist foam is optionally present in the
absorbent article and positioned near and adjacent to the front
edge 100 and/or back edge 110, on the skin-facing surface of the
permeable topsheet 40.
[0074] Referring still to FIG. 3, a polymer barrier 10 is shown.
The polymer barrier 10 is disposed between the permeable topsheet
40 and the substantially impermeable backsheet 50. On the portion
of the absorbent article corresponding to the absorbent core 8, the
polymer barrier 10 is disposed between the absorbent core 8 and the
substantially impermeable backsheet 50. The polymer barrier 10 is
transversely positioned between the leg cuffs 4a and 4b and extends
from about the front edge 100 to about the back edge 110. The inner
leg gathers 2a and 2b are disposed on the skin-facing surface of
the permeable topsheet 40 and are bonded thereto.
[0075] Referring to FIG. 4, a cross-sectional view of an absorbent
article according to the implementation of the present invention
show in FIG. 1 is shown. The polymer barrier 10 is shown disposed
between the substantially impermeable backsheet 50 and the
permeable topsheet 40. Further, the polymer barrier 10 is shown as
being disposed between the absorbent core 8 and the substantially
impermeable backsheet 50 at the portion of the polymer barrier 10
that corresponds to the absorbent core 8.
[0076] Referring still to FIG. 4, the leg cuffs 4a and 4b are shown
as being positioned outward of the polymer barrier 10 and along
each inner leg gather 2a and 2b and the substantially impermeable
backsheet 50. In this manner, the leg cuffs 4a and 4b are bonded to
a portion of each of the inner leg gathers 2a and 2b and/or the
substantially impermeable backsheet 50. Accordingly, as illustrated
in the figure, the leg cuffs 4a and 4b are not bonded to the
polymer barrier 10. Thus, the leg cuffs 4a and 4b comprise the
softer material of the inner leg gathers 2a and 2b and/or the
substantially impermeable backsheet 50 rather than the stiffer
polymer material of the polymer barrier 10.
[0077] Referring to FIG. 5, an absorbent article is shown from a
top perspective with the skin-facing surface of the permeable
topsheet 40 and the skin-facing surface of the substantially
impermeable backsheet 50 visible. The absorbent article comprises a
front edge 100, a back edge 110, two front-side edges 120a and
120b, two back-side edges 140a and 140b, and two leg cutout edges
130a and 130b, positioned such that leg cutout edge 130a is
disposed between front-side edge 120a and back-side edge 140a, and
leg cutout edge 130b is disposed between front-side edge 120b and
back-side edge 140b. The absorbent article further comprises two
inner leg gathers 2a and 2b, each of which extends longitudinally
along the permeable topsheet 40 of the absorbent article from the
back edge 110 to the front edge 100. The inner leg gathers 2a and
2b are approximately parallel to one another and are each
positioned approximately parallel to the front-side and back-side
edges 120a, 120b, 140a and 140b. Further, each inner leg gather is
located adjacent to and inward of the inner most portion of the leg
cutout edges 130a and 130b. A pair of front wing regions are
defined as the area between each front-side edge and its adjacent
inner leg gather, forward of the leg cutouts. A pair of back wing
regions are defined as the area between adjacent back-side edge and
its adjacent inner leg gather, rearward of the leg cutouts.
[0078] As further shown in FIG. 5, the absorbent article further
comprises two leg cuffs 4a and 4b, each of which is positioned
approximately adjacent and parallel to each of the inner leg
gathers 2a and 2b. Each of the leg cuffs is located outward of said
inner leg gathers 2a and 2b. Two fasteners 6a and 6b are each
located at or near the back side edge of the absorbent article. An
absorbent core 8 is shown as being disposed between the permeable
topsheet 40 and a substantially impermeable backsheet 50 (not shown
in FIG. 1). The absorbent core 8 is positioned longitudinally along
the absorbent article. Waist foam is optionally present in the
absorbent article and positioned near and adjacent to the front
edge 100 and/or back edge 110, on the skin-facing surface of the
permeable topsheet 40.
[0079] Referring still to FIG. 5, a polymer barrier 10 is shown.
The polymer barrier 10 is disposed between the permeable topsheet
40 and the substantially impermeable backsheet 50. On the portion
of the absorbent article corresponding to the absorbent core 8, the
polymer barrier 10 is disposed between the absorbent core 8 and the
substantially impermeable backsheet 50. The polymer barrier 10 is
transversely positioned between the leg cuffs 4a and 4b and extends
from about the front edge 100 to about the back edge 110. The inner
leg gathers 2a and 2b are disposed on the skin-facing surface of
the permeable topsheet 40 and are bonded thereto.
[0080] Referring to FIG. 6, a cross-sectional view of an absorbent
article according to the implementation of the present invention
show in FIG. 1 is shown. The polymer barrier 10 is shown disposed
between the substantially impermeable backsheet 50 and the
permeable topsheet 40. Further, the polymer barrier 10 is shown as
being disposed between the absorbent core 8 and the substantially
impermeable backsheet 50 at the portion of the polymer barrier 10
that corresponds to the absorbent core 8.
[0081] Referring still to FIG. 6, the leg cuffs 4a and 4b are shown
as being positioned outward of the polymer barrier 10 and about the
substantially impermeable backsheet 50. In this manner, the leg
cuffs 4a and 4b are bonded to the substantially impermeable
backsheet 50. Accordingly, as illustrated in the figure, the leg
cuffs 4a and 4b are not bonded to the polymer barrier 10. Thus, the
leg cuffs 4a and 4b comprise the softer material (i.e., soft
nonwoven material) of the substantially impermeable backsheet 50
rather than the stiffer polymer material of the polymer barrier
10.
[0082] The novel configuration illustrated in the figures herein
unexpectedly provides protection against leakage directly through
the substantially impermeable backsheet while dramatically
improving comfort for the wearer. A further unexpected benefit of
the novel configuration is that the softer material provides for an
improved fit about the legs of the wearer, thereby providing
unexpectedly superior lateral leak protection (e.g., protection
against leakage at the leg openings). This further enhances comfort
to the wearer, as well as providing skin wellness benefits to the
wearer. Moreover, the absorbent articles in accordance with the
present invention are highly cost-efficient in addition to
providing the foregoing superior characteristics.
[0083] According to an implementation of the present invention, an
absorbent article comprises: a substantially impermeable backsheet;
a permeable topsheet; an absorbent core disposed between the
substantially impermeable backsheet and the permeable topsheet; a
pair of leg cuffs, each of said leg cuffs being disposed adjacent
to the longitudinal side edges of the absorbent article; and a
polymer barrier disposed between the substantially impermeable
backsheet and the absorbent core, said polymer barrier being
transversely positioned between the leg cuffs, such that the
transverse width of the polymer barrier is at least the transverse
width of the absorbent core and the transverse width of the polymer
barrier is no greater than the distance between the innermost
portion of each of the leg cuffs.
[0084] Suitable leg cuffs include any leg cuffs that hold the leg
openings of the absorbent article or garment snug to the legs of a
wearer of the absorbent article or garment. The leg cuffs may be
elastic leg cuffs or the like. The leg cuffs comprise a soft
nonwoven material. Optionally, the leg cuffs are directly bonded to
the substantially impermeable backsheet, the permeable topsheet
and/or the inner leg gathers and any such combination.
[0085] The soft nonwoven material comprises fibers that are
sufficiently fine to feel comfortable against the skin of a wearer
during use, including during prolonged or extended use, ranging
from perhaps a few hours to an entire evening and nighttime. The
fineness of the fibers in the soft nonwoven material ranges from
about 0.90 dtex to about 4.5 dtex. Preferably, the fineness of the
fibers is about 1.00 dtex to about 3.50 dtex. More preferably, the
fineness of the fibers is about 1.25 dtex to about 3.00 dtex. Even
more preferably, the fineness of the fibers is about 1.25 dtex to
about 2.75 dtex. The soft nonwoven material may comprise a variety
of suitable fibers effective in implementations of the present
invention. A person skilled in the art would readily be able to
select a suitable soft nonwoven material in accordance with the
present invention.
[0086] Suitable soft nonwoven materials may be prepared using a
variety of methods and techniques well known in the art. For
example, soft nonwoven materials may be prepared using conventional
processes such as spun-bonding, melt-blowing, heat rolling, suction
heat bonding and air-through bonding, without limitation.
[0087] Non-limiting exemplary fibers include spun-laced fibers,
spun-bonded fibers, melt-blown fibers and combinations thereof. The
soft nonwoven material may be of a variety of suitable substances.
Non-limiting exemplary nonwoven materials include polyester,
polypropylene, polyethylene and combinations thereof. Persons of
ordinary skill in the art would readily be able to select and/or
prepare suitable fibers in accordance with implementations of the
present invention using conventional skills and techniques, based
upon the guidance provided herein.
[0088] The substantially impermeable backsheet may comprise a
nonwoven layer. The nonwoven layer may comprise a variety of
suitable materials. Preferably, the nonwoven layer is a soft
nonwoven material or a combination of soft nonwoven materials,
without limitation. More preferably, the nonwoven layer is a soft
nonwoven material or combinations thereof and the soft nonwoven
material comprises fibers selected from the group consisting of
polyester fibers, polypropylene fibers, polyethylene fibers and
combinations thereof, without limitation.
[0089] The absorbent article and/or absorbent garment is configured
so that the polymer barrier provides adequate leak protection. For
example, the longitudinal side edges of the polymer barrier are
positioned at an effective distance from the adjacent
longitudinally disposed side edges of the absorbent core to provide
protection from leakage through the substantially impermeable
backsheet while avoiding contact with the legs of the wearer during
use. A person skilled in the art would readily be able to select a
suitable effective distance in accordance with the present
invention.
[0090] The absorbent article and/or absorbent garment is further
configured so that the polymer barrier does not come into contact
with the legs of the wearer of the absorbent article and/or garment
during use. For example, each longitudinal side edge of the polymer
barrier is positioned an effective distance from the inner edge of
each leg cuff. A person skilled in the art would readily be able to
select a suitable effective distance in accordance with the present
invention.
[0091] The absorbent core of the present invention may be of a
variety of suitable shapes and sizes. Persons of ordinary skill in
the art would be readily able to prepare suitable absorbent cores
for the absorbent articles and garments of the present invention.
Preferably, the absorbent core of the present invention is
approximately rectangular.
[0092] The polymer barrier may be of a variety of shapes and sizes
that are suitable for the absorbent articles and garments of the
present invention, as would be recognized by persons of ordinary
skill in the art. Preferably, the polymer barrier of the present
invention is approximately rectangular, without limitation.
[0093] Optionally, the articles and garments of the present
invention further comprise a pair of inner leg gathers disposed on
the permeable topsheet, each of said inner leg gathers being
positioned outward of a side edge of the absorbent core and inward
of the nearest leg cuff. The transverse width of the polymer
barrier may be less than, greater than or about equal to the
transverse distance between the inner leg gathers. Preferably, the
transverse width of the polymer barrier is greater than the
transverse distance between the inner leg gathers.
[0094] According to an implementation of the present invention, an
absorbent garment comprises: front and rear waist portions
cooperating to form a waist opening; a crotch region formed between
said front and rear waist portions; a pair of leg openings on
opposed sides of the crotch region; a permeable topsheet; a
substantially impermeable backsheet; an absorbent core disposed
between the permeable topsheet and the substantially impermeable
backsheet; a pair of stand-up elasticized leg gathers having a
distal edge and a proximal edge and positioned inward of said leg
openings on opposite sides of a longitudinal center line of the
absorbent garment, said leg gathers comprising a non-woven
material; a pair of leg cuffs, each of said leg cuffs being
disposed adjacent to the longitudinal side edges of the absorbent
article; and a polymer barrier disposed between the substantially
impermeable backsheet and the absorbent core, said polymer barrier
being transversely positioned between the leg cuffs, such that the
transverse width of the polymer barrier is at least the transverse
width of the absorbent core and the transverse width of the polymer
barrier is no greater than the distance between the innermost
portion of each of the leg cuffs.
[0095] A wide variety of permeable topsheets are suitable for the
absorbent articles and garments of the present invention. For
example, the permeable topsheet of the absorbent garment in
accordance may have a basis weight of about 0.6 ounces per square
yard, without limitation. Further, the permeable topsheet may
comprise a central liquid permeable portion and a pair of side
marginal portions joined to respective opposite side edges of said
central portion, said side marginal portions comprising spun-bond,
melt-blown, spun-bond (SMS) non-woven material having a basis
weight in the range of about 0.3-0.8 ounces per square yard, said
central portion of said topsheet comprising a spun-bond
polypropylene non-woven fabric, without limitation.
[0096] The substantially impermeable backsheet comprises a
non-woven material. The non-woven material may be of a wide variety
of suitable materials as would be readily apparent to persons of
ordinary skill in the art, based upon the disclosure provided
herein. Preferably, the nonwoven material is selected from the
group consisting of spun-laced fibers, spun-bonded, melt-blown
fibers and combinations thereof, without limitation. More
preferably, the nonwoven material comprises fibers of a material
selected from the group consisting of polyester, polypropylene,
polyethylene and combinations thereof, without limitation.
[0097] According to an implementation of the present invention, an
absorbent garment comprises: front and rear waist portions
cooperating to form a waist opening; a crotch region formed between
said front and rear waist portions; a pair of leg openings on
opposed sides of the crotch region; a permeable topsheet, a
substantially impermeable backsheet, and an absorbent core
positioned between said permeable topsheet and said substantially
impermeable backsheet; a pair of leg cuffs, each of said leg cuffs
extending at least through the crotch region adjacent to each leg
opening and positioned between said permeable topsheet and
substantially impermeable backsheet; and a polymer barrier disposed
between the substantially impermeable backsheet and the absorbent
core, said polymer barrier being transversely positioned between
the leg cuffs, such that the transverse width of the polymer
barrier is at least the transverse width of the absorbent core and
the transverse width of the polymer barrier is no greater than the
distance between the innermost portion of each of the leg
cuffs.
[0098] In accordance with an implementation of the present
invention, an absorbent article is substantially evenly distributed
around the body of the wearer during use. Even distribution of the
absorbent article is facilitated through the novel configuration of
the polymer barrier and the leg cuffs. The even distribution
improves fit and comfort of the absorbent article and consequently
provides unexpectedly superior leakage protection.
[0099] Due to the wide variety of materials which may be
incorporated into the absorbent articles of the present invention,
the present invention is not intended to be limited to any specific
materials. The permeable topsheet, substantially impermeable
backsheet, absorbent core and other components of the absorbent
articles in accordance with various implementations of the present
invention may comprise various materials. Persons of ordinary skill
in the art would be readily able to select appropriate materials
for use in the various components of the present invention based
upon the materials.
[0100] In accordance with various implementations of the present
invention, the absorbent core may contain one or more fibers, one
or more polymers or combinations thereof. Non-limiting exemplary
fibers which may be used in the articles of the present invention
include, without limitation, cellulose fibers, cellulose acetate
fibers, rayon fibers, Courtauld's LYOCEL fibers, polyacrylonitrile
fibers, surface modified (hydrophilic) polyester fibers, surface
modified polyolophin/polyester by component fibers, surface
modified polyester/polyester bicomponent fibers, cotton fibers or
blends thereof. Preferably, cellulose acetate, rayon, Courtauld's
LYOCEL, polyacrylonitrile, cotton fibers and cotton linters or
combinations thereof are used in the present invention. More
preferably, cellulose fibers are used as fiber material in the
present invention.
[0101] Other materials may be added to fiber or pulp material which
is optionally processed in a fiberizing apparatus, such as a
hammermill. The additives may be added at any point in the process.
Preferably, the additives are sprayed or injected into the airborne
fibers prior to the depositing of the fibers on a forming surface.
Non-limiting exemplary additives which may be incorporated into the
process of the present invention include a polymer such as a super
absorbent polymer (SAP), hydrophilic polymers, potato starch, corn
starch, wheat starch or rice starch, or combinations thereof.
[0102] Various different combinations of materials may be used as
are known to persons of ordinary skill in the art and which are
described in U.S. Pat. No. 6,068,620 which is herein incorporated
by reference. Preferably, the mixtures incorporated in the
invention are substantially homogenous mixtures or uniformly
distributed mixtures. Absorbent articles in accordance with an
implementation of the present invention are prepared using
conventional methods and materials well known to persons of
ordinary skill in the art, using the guidelines provided
herein.
[0103] The present invention further provides absorbent garments
that include the absorbent article of the present invention.
Non-limiting exemplary absorbent garments include diapers, adult
incontinent products, feminine hygiene products, disposable
sanitary products and the like. Non-limiting exemplary diapers
include daytime diapers, nighttime diapers, daytime/nighttime
diapers, long-term wear diapers, male diapers, female diapers,
unisex diapers, travel diapers, medicated diapers, swimming diapers
and the like.
[0104] The present invention has been described in connection with
the preferred embodiments. These embodiments, however, are merely
for example and the invention is not restricted thereto. Any
examples described herein are illustrative of preferred embodiments
of the inventive subject matter and are not to be construed as
limiting the inventive subject matter thereto. It will be
understood by persons skilled in the art that other variations and
modifications can easily be made within the scope of the invention
as defined by the appended claims.
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